Lower fork alignment system

ABSTRACT

A lower fork alignment system for a vehicle is described. The lower fork alignment system includes: a brace detachably coupling a first lower tube and a second lower tube of a lower fork, wherein the first and second lower tubes include: first and second receiving adjustment mechanism configured for receiving corresponding interfacing mechanisms of the brace, wherein upon receipt of alignment features of the interfacing mechanisms, one of the first lower tube and the second lower tube is enabled to be adjusted in a horizontal direction along a horizontal axis, and the other of the first lower tube and the second lower tube is enabled to be adjusted in a vertical direction along a vertical axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation application of and claims thebenefit of co-pending U.S. patent application Ser. No. 16/678,858, filedNov. 8, 2019, entitled, “LOWER FORK ALIGNMENT SYSTEM”, by Mario Galasso,having Attorney Docket No. FOX-P4-30-14-US.DIV.CON2, assigned to theassignee of the present application, which is incorporated herein in itsentirety by reference thereto.

The patent application Ser. No. 16/678,858 is a continuation applicationof and claims the benefit of U.S. patent application Ser. No.16/044,193, filed Jul. 24, 2018, now U.S. Issued U.S. Pat. No.10,472,017, entitled, “LOWER FORK ALIGNMENT SYSTEM”, by Mario Galasso,having Attorney Docket No. FOX-P4-30-14-US.DIV.CON, assigned to theassignee of the present application, which is incorporated herein in itsentirety by reference thereto.

The patent application Ser. No. 16/044,193 is a continuation applicationof and claims the benefit of U.S. patent application Ser. No.15/614,314, filed Jun. 5, 2017, now U.S. Issued U.S. Pat. No.10,040,505, entitled, “LOWER FORK ALIGNMENT SYSTEM”, by Mario Galasso,having Attorney Docket No. FOX-P4-30-14-US.DIV, assigned to the assigneeof the present application, which is incorporated herein in its entiretyby reference thereto.

The patent application Ser. No. 15/614,314 is a divisional applicationof and claims the benefit of U.S. patent application Ser. No.14/505,342, filed Oct. 2, 2014, now U.S. Issued U.S. Pat. No. 9,669,892,entitled, “LOWER FORK ALIGNMENT SYSTEM”, by Mario Galasso, havingAttorney Docket No. FOX-P4-30-14-US, assigned to the assignee of thepresent application, which is incorporated herein in its entirety byreference thereto.

The patent application Ser. No. 14/505,342 claims priority to andbenefit of U.S. provisional patent application 62/053,618, filed Sep.22, 2014, entitled, “LOWER FORK ALIGNMENT SYSTEM”, by Mario Galasso,having Attorney Docket No. FOX-P4-30-14-US.PRO, assigned to the assigneeof the present application, which is incorporated herein in its entiretyby reference thereto.

FIELD OF THE INVENTION

Embodiments of the present technology relate generally to the field ofwheeled vehicles.

BACKGROUND

A bicycle fork is the part of a bicycle that holds the front wheel andallows the rider to steer and balance the bicycle. The fork may consistof two telescopic tubes connected by a brace that keeps the telescopictubes in parallel to one another during use.

Conventionally, during manufacturing, these telescopic tubes andconnecting brace are cast and molded as a single piece. Typically,during the casting process, liquid metal is injected into a mold and letto cool to solidity. The flow patterns caused by the injection of theliquid metal introduce residual stress to the casted fork. Thus, due tothis residual stress, the casted fork has a tendency to bend.Consequently, many times, the casted two fork legs, connected by thebrace, are not quite parallel with each other. When upper fork legs areinserted into the casted and slightly unparallel lower legs, stictionmay result, thereby making it more difficult for a suspension system tofunction as intended. Stiction refers to friction between the upper andthe lower legs of the fork. Thus, limitations exist in conventionalsystems and methods relating to the vehicle fork legs. What is needed isa system and method of manufacture of lower fork legs that reduces thefriction between the upper and the lower fork legs during operation.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present invention are illustrated by way of example, andnot by way of limitation, in the accompanying drawings, wherein:

FIG. 1 is a perspective view of a conventional bicycle, in accordancewith an embodiment.

FIG. 2 is a perspective view of a front fork having a spring and dampertherein.

FIG. 3 is a front perspective view of a relevant portion of a lower forkwith a partial illustration of an attached brace and receivingadjustment mechanisms, in accordance with an embodiment.

FIG. 4 is a rear perspective view of an inner structure of the brace ofFIG. 3 showing interfacing mechanisms, in accordance with an embodiment.

FIG. 5 is an enlarged perspective view of section A-A of FIG. 4, inaccordance with an embodiment.

FIG. 6 is an enlarged perspective view of section B-B of FIG. 4, inaccordance with an embodiment.

FIG. 7 is a % perspective view of the lower tubes shown in FIG. 3, inaccordance with an embodiment.

FIG. 8 is a % perspective view of the brace of FIG. 3, screws forinserting into the brace, and molded covers for covering the screws, inaccordance with an embodiment.

FIG. 9 is a front perspective view of the brace of FIG. 3 coupling theright lower tube and the left lower tube, in accordance with anembodiment.

FIG. 10 is a % perspective view of the brace of FIG. 3 coupling theright lower tube and the left lower tube, in accordance with anembodiment.

FIG. 11 is a % perspective view of an exploded perspective view of abrace, a right lower tube and a left lower tube, in accordance with anembodiment.

FIG. 12 is a front cross-sectional view of the brace of FIG. 11 couplingthe right lower tube and the left lower tube, in accordance with anembodiment.

FIG. 13 is a side perspective view of assembled embodiments of FIG. 12,in accordance with an embodiment.

FIG. 14 is an enlarged front cross-sectional view of area A of FIG. 12,in accordance with an embodiment.

FIG. 15 is a front perspective view of a brace coupled to a right and aleft lower tube, in accordance with an embodiment.

FIG. 16 is a side perspective view of the assembled brace of FIG. 15 andthe right and left lower tubes, in accordance with an embodiment.

FIG. 17 is an enlarged front perspective view of the area A of FIG. 15,in accordance with an embodiment.

The drawings referred to in this description should be understood as notbeing drawn to scale except if specifically noted.

SUMMARY OF EMBODIMENTS

One embodiment is a lower fork alignment system that includes: a bracedetachably coupling a first lower tube and a second lower tube of alower fork, wherein the first and second lower tubes include: first andsecond receiving adjustment mechanism configured for receivingcorresponding interfacing mechanisms of the brace, wherein upon receiptof alignment features of the interfacing mechanisms, one of the firstlower tube and the second lower tube is enabled to be adjusted in ahorizontal direction along a horizontal axis, and the other of the firstlower tube and the second lower tube is enabled to be adjusted in avertical direction along a vertical axis.

One embodiment includes a lower fork alignment system for a vehicle.According to the embodiment, the lower fork alignment system includes: alower fork that includes: a brace coupling a first lower tube to asecond lower tube, wherein the first lower tube includes: a firstreceiving adjustment mechanism disposed at a first end of the firstlower tube, wherein the first receiving adjustment mechanism isconfigured for receiving a corresponding first interfacing mechanism ofthe brace, wherein the first receiving adjustment mechanism includes: afirst alignment feature enabling a horizontal adjustment of the firstlower tube relative to the second lower tube and along a horizontalaxis. The second lower tube includes: a second receiving adjustmentmechanism disposed at a first end of the second lower tube. The secondreceiving adjustment mechanism is configured for receiving acorresponding second interfacing mechanism of the brace. The secondreceiving adjustment mechanism includes: a second alignment featureenabling a vertical adjustment of the second lower tube relative to thefirst lower tube and along a vertical axis.

One embodiment includes a brace for coupling a first lower tube to asecond lower tube of a lower fork. The brace includes: a first end; asecond end; a first interfacing mechanism disposed at the first end,wherein the first interfacing mechanism is configured for being insertedinto a corresponding first receiving adjustment mechanism of a firstlower tube of a lower fork and includes: at least one raised horizontalrectangular shape configured for being inserted into the first receivingadjustment mechanism of the first lower tube, wherein upon receipt, thefirst lower tube may be slid in a horizontal direction along ahorizontal axis; and a second interfacing mechanism disposed at thesecond end, wherein the second interfacing mechanism is configured forbeing inserted into a corresponding second receiving adjustmentmechanism of a second lower tube of a lower fork and includes: at leastone raised vertical rectangular shape configured for being inserted intothe second receiving adjustment mechanism of the second lower tube,wherein upon receipt, the second lower tube may be slid in a verticaldirection along a vertical axis.

One embodiment includes a lower tube of a lower fork of a vehicle. Thelower tube includes: a receiving adjustment mechanism disposed at afirst end of the lower tube, wherein the receiving adjustment mechanismis configured for receiving a corresponding interfacing mechanism of abrace. The receiving adjustment mechanism includes: an alignment featureenabling one of a horizontal adjustment and a vertical adjustment of thelower tube relative to another lower tube of the lower fork and adjustedalong one of a horizontal axis and a vertical axis, respectively.

DESCRIPTION OF EMBODIMENTS

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various embodiments of thepresent invention and is not intended to represent the only embodimentsin which the present invention may be practiced. Each embodimentdescribed in this disclosure is provided merely as an example orillustration of the present invention, and should not necessarily beconstrued as preferred or advantageous over other embodiments. In someinstances, well known methods, procedures, objects, and circuits havenot been described in detail as not to unnecessarily obscure aspects ofthe present disclosure.

This patent application describes the invention in the context of anexample embodiment of the lower front fork for a bicycle. However, theteachings and scope of the invention are equally applicable to otherlower fork assemblies for any two-wheeled vehicle.

Overview of Discussion

Embodiments disclosed herein include a lower fork alignment system forcoupling two lower fork legs together with a brace and enabling improvedalignment of the left and right lower fork legs of a bicycle by allowingfor mid-assembly horizontal, vertical and rotational adjustment of thelower fork legs via the brace. Significantly, the brace, the right lowertube and the left lower tube are assembled after being manufactured asseparate pieces. During assembly, pieces may be individually adjusted toattain a desired alignment relative to each other. When properlyaligned, the telescopic movement of the upper tubes within the lowertubes remains near or at the lowest friction level. Once the lower forklegs are positionally adjusted such that the lower fork legs are alignedwithin the same horizontal and vertical planes, then embodiments enablethe stabilization of these adjusted positions through attachmentfeatures found in both the brace and the lower fork legs (e.g., boltholes, screw holes, glue cavities, etc.).

The following discussion will begin with a brief description of aconventional bicycle (See FIG. 1), a conventional bicycle front lowerfork manufactured as a single molded piece (See FIG. 2), and theproblems associated therewith. The discussion turns to a description ofvarious embodiments, including: a brace that is attached to the lowerfork legs using horizontal and vertical attachment bars (See FIGS.3-10); a brace that couples lower fork legs using a matching positiveand negative spline features and is glued onto lower fork legs (SeeFIGS. 11-14); and a center bridge that may be used as a brace or as partof a brace of prior described embodiments (See FIGS. 15-17).

FIG. 1 illustrates an off-road bicycle, or mountain bike 100, includinga frame 114 which is comprised of a main frame portion 108 and a swingarm portion 116. The swing arm portion 116 is pivotally attached to themain frame portion 108. The bicycle 100 includes front and rear wheels104 and 118, respectively, connected to the main frame 108. A seat 110is connected to the main frame 108 in order to support a rider of thebicycle 100.

The front wheel 104 is supported by a front fork 102 which, in turn, issecured to the main frame 108 by a handlebar assembly 106. The rearwheel 118 is connected to the swing arm portion 104 of the frame 114. Arear shock 112 is positioned between the swing arm 116 and the frame 108to provide resistance to the pivoting motion of the swing arm 116. Thus,the illustrated bicycle 100 includes suspension members between thefront and the rear wheels 104 and 118, respectively, and the frame 114,which operate to substantially reduce wheel impact forces from beingtransmitted to the rider of the bicycle 100.

FIG. 2 illustrates the front fork 102 as being detached from the bicycle100 of FIG. 1. The front fork 102 include right and left legs, 202 and220, respectively, as referenced by a person in a riding position on thebicycle 100. The right leg 202 includes a right upper tube 208telescopingly received in a right lower tube 204. Similarly, the leftleg 220 includes a left upper tube 214 telescopingly received in a leftlower tube 218. A crown 210 connects the right upper tube 208 to theleft upper tube 214 thereby connecting the right leg 202 to the left leg220 of the front fork 102. In addition, the crown 210 supports a steerertube 212, which passes through, and is rotatably supported by, the frame114 of the bicycle 100. The steerer tube 212 provides a means forconnection of the handlebar assembly 106 to the front fork 102, asillustrated in FIG. 1.

Each of the right lower tube 204 and the left lower tube 218 includesdropouts 224 and 226, respectively, for connecting the front wheel 104to the front fork 102. An arch 216 connects the right lower tube 204 andthe left lower tube 218 to provide strength and minimize twistingthereof. The right lower tube 204, the left lower tube 218 and the arch216 are formed as a unitary piece.

As the right lower tube 204, the left lower tube 218 and the arch 216are formed as a unitary piece, it is not possible to make horizontal andvertical adjustments after the unitary piece has been casted. Therefore,due to the casting process, and the shrinking of the materialpost-casting, the resulting unitary piece has a tendency to bend. Whenportions of the unitary piece bends, such as when one or both of theright lower tube 204 and the left lower tube 218 slightly bend and/ortwist, the right upper tube 208 and the left upper tube 214 havedifficult sliding in and out of the right and left lower tubes 204 and218, respectively, since friction occurs there between because the uppertubes 208 and 214 rub against the lower tubes 204 and 218.

Example Lower Fork Alignment System

Embodiments provide for the separate manufacture of a right lower tube,a left lower tube and a brace that connects the right and left lowertubes via receiving adjustment mechanisms, interfacing mechanisms andattachment mechanisms. The lower fork alignment system provided hereinenables the horizontal and vertical alignment adjustment of the rightlower tube, the left lower tube and/or the brace. Such alignmentadjustment possibilities enable the right lower tube and the left lowertube to be adjusted to a desired alignment position relative to eachother, thereby reducing the friction that develops due to improperlyaligned lower fork tubes or the bending of lower forks due topost-casting stress.

FIG. 3 illustrates a brace coupling a right and left lower tubetogether, along with receiving adjustment mechanisms attached thereto,in accordance with an embodiment. More specifically, FIG. 3 shows afront fork 300 including a right upper tube 306 telescopically engagedwith the right lower tube 302, and a left upper tube 310 telescopicallyengaged with a left lower tube 316. A right receiving adjustmentmechanism 304 and a left receiving adjustment mechanism 314 are attachedto the right lower tube 302 and the left lower tube 316, respectively.In one embodiment, the receiving adjustment mechanisms are molded ontothe lower tubes in a casting process. However, in another embodiment,the receiving adjustment mechanisms are attached to the lower tubes in amanner suitable for operation with the vehicle, such as with bolts,screws, glue, etc.

In one embodiment, the right receiving adjustment mechanism 304 includeshorizontal alignment features that constitute one or more depressionsformed in a horizontal rectangular (bar) shape. The horizontalrectangular (bar) shape depression 318 formed within the right receivingadjustment mechanism 304 is configured to receive a raised horizontalrectangular (bar) shape formed on the brace 308 (as will be explained indetail with respect to FIGS. 4-6), such that the raised horizontalrectangular shape partially fills the horizontal bar shape depression318. As shown, the right receiving adjustment mechanism 304 includes twohorizontal rectangular shape depressions. It should be appreciated thatembodiments may include one or more horizontal rectangular shapedepressions.

As will be explained herein in more detail, the raised horizontalrectangular shape of the brace 308 will fit into the horizontalrectangular shape depression 318 such that the brace 308 may beshifted/adjusted horizontally by sliding the brace 308 in a directionalong the horizontal axis 324. The raised horizontal rectangular shapeis slid within the horizontal rectangular shape depression 318 until adesired distance between the right lower tube 302 and the left lowertube 316 is achieved. Of note, when providing the adjustment, the otherend of the brace 308 is concurrently inserted into the left receivingadjustment mechanism 314 such that the brace 308 is coupled with theleft lower tube 316.

In one embodiment, the left receiving adjustment mechanism 314 includesvertical alignment features that constitute one or more depressionsformed in a vertical rectangular (bar) shape. The vertical rectangular(bar) shape depression 320 formed within the left receiving adjustmentmechanism 314 is configured to receive a raised vertical rectangular(bar) shape formed on the brace 308 (as will be explained in detail withrespect to FIGS. 4-6), such that the raised vertical rectangular shapepartially fills the vertical bar shape depression 320. As shown, theleft receiving adjustment mechanism 320 includes two verticalrectangular shape depressions. It should be appreciated that embodimentsmay include one or more vertical rectangular shape depressions.

As will be explained herein in more detail, the raised verticalrectangular shape of the brace 308 will fit into the verticalrectangular shape depression 320 such that the brace 308 may beshifted/adjusted vertically by sliding the brace 308 in a directionalong the vertical axis 326. The raised vertical rectangular shape isslid within the vertical rectangular shape depression 320 until adesired vertical height of the left lower tube 316 relative to the rightlower tube 302 is achieved. Of note, when providing the adjustment, theother end of the brace 308 is concurrently inserted into the rightreceiving adjustment mechanism 304 such that the brace 308 is coupledwith the right lower tube 302.

It should also be appreciated that while the discussion focuses on thefeatures (e.g., horizontal rectangular shape depression 318, etc.)attributed to the right receiving adjustment mechanism 304 and features(e.g., vertical rectangular shape depression 320, etc.) attributed toleft receiving adjustment mechanism 314, the horizontal rectangularshape depression 318, in one embodiment, may be formed in the leftreceiving adjustment mechanism 314. Likewise, in one embodiment, thevertical rectangular shape depression 320 may be formed in the rightreceiving adjustment mechanism 304. Further, the corresponding raisedhorizontal rectangular shape and the raised vertical rectangular shapeare formed on either end of the brace 308.

FIG. 3 also show attachment mechanisms 312 and 322, that being screwholes (or a first and second set of screw holes, wherein each “set” maycontain one or more screw holes) configured for receiving screws uponthe insertion of the raised horizontal and vertical rectangular shapesinto the horizontal rectangular shape and vertical rectangular shapedepressions, 318 and 320, respectively, formed in the right and leftreceiving adjustment mechanisms, 304 and 314, respectively. It should beunderstood that the attachment mechanism for maintaining the brace 308firmly attached to the lower fork 300 may be any suitable means. Innon-limiting examples, bolts, screws and/or glue may be used to attachthe brace 308 to the right and left receiving adjustment mechanisms, 304and 314, respectively. It should be noted that in one embodiment, theattachment mechanism that receives the glue is a cavity capable ofreceiving and holding the glue such that the glue may bond componentstogether.

FIG. 4 illustrates a rear view of an inner structure of the brace 308comprising a right interfacing mechanism 408 at a first end 406 and aleft interfacing mechanism 404 at the second end 402, in accordance withan embodiment. In one embodiment, the right interfacing mechanism 408has formed thereon at least one raised vertical rectangular shape 412,and the left interfacing mechanism 404 has formed thereon at least oneraised horizontal rectangular shape 410. FIG. 5 is an enlargedperspective view of section A-A of FIG. 4, showing a raised horizontalrectangular shape of the at least one raised horizontal rectangularshape 412, in accordance with an embodiment. FIG. 6 is an enlargedperspective view of section B-B of FIG. 4, showing a raised verticalrectangular shape of the at least one raised vertical rectangular shape410, in accordance with an embodiment.

As described herein, the at least one raised horizontal rectangularshape 412 is formed such that it fits into the at least one horizontalrectangular shape depression 318. Once inserted into the at least onehorizontal rectangular shape depression 318, the at least one raisedhorizontal rectangular shape 412 may be slid horizontally in ahorizontal direction along the horizontal axis 324, to adjust the rightlower tube 302 in relation to the left lower tube 316. The at least oneraised vertical rectangular shape 410 is formed such that it fits intothe at least one vertical rectangular shape depression 320. Onceinserted into the at least one vertical rectangular shape depression320, the at least one raised horizontal rectangular shape 410 (and hencethe left lower tube 316) may be slid vertically in a vertical directionalong the vertical axis 326, to adjust the left lower tube 316 inrelation to the right lower tube 302.

FIG. 7 illustrates the left lower tube 316 and the right lower tube 302,having attached thereon the left receiving adjustment mechanism 314 andthe right receiving adjustment mechanism 304, respectively, inaccordance with an embodiment.

FIG. 8 illustrates, according to an embodiment, the brace 308, set ofscrews 802 and 804 for inserting into the brace 308 and the right andleft receiving adjustment mechanisms 304 and 314, respectively, andmolded covers 806A and 806B for covering the set of screws 802 and 804,respectively.

With reference now to FIGS. 7 and 8, a method of assembling embodimentsprovided herein may be described. For example, the first end 406 of thebrace 308 is placed onto the right receiving adjustment mechanism 304.The second end 402 of the brace 308 is placed onto the left receivingadjustment mechanism 314. Then, the brace 308 or the right lower tube302 is adjusted horizontally along the horizontal axis 324 and/or thebrace 308 or the left lower tube 316 is adjusted vertically along thevertical axis 326.

Once the brace 308 is adjusted as desired in relation to the right lowertube 302 and the left lower tube 316, then the set of screws 802 and 804are inserted into the attachment mechanisms 312 and 322, respectively.As noted, while in one embodiment screws are used, it should beappreciated that any suitable manner of attachment may be used to attachthe brace 308 to the right lower tube 302 and the left lower tube 316.

Once the set of screws 806A and 806B are inserted into the attachmentmechanisms 312 and 322, respectively, then molded covers 806A and 806Bare placed over the visible heads of the set of screws 806A and 806B,respectively. The molded cover is formed to cover the screws, bolts,etc., and is made of plastic, in one embodiment. The molded cover, inone embodiment, slips over and around the heads of the screws or bolts,and includes any manner of suitable mechanisms enabling attachment tothe screws or bolts. For example, in one embodiment, the molded covermay be formed such that the molded cover stretches slightly and itsouter edges contain a lip that curves inward and under the molded coverand that enables the molded cover to slip over and around the outeredges of the screws or bolts. In another embodiment, glue is used tohold the molded cover in place.

FIGS. 9 and 10 illustrate assembled embodiments of the lower forkalignment system, wherein the brace 308 couples the right lower tube 302with the left lower tube 316, the set of screws 802 and 804 attaches thebrace 308 to the right and left lower tubes 302 and 316, respectively.Molded covers 806A and 806B are also shown covering (hiding) the headsof the set of screws 802 and 804, respectively.

FIG. 11 illustrates a brace 1106 for coupling the right lower tube 1104and the left lower tube 1102, in accordance with an embodiment. Theright lower tube 1104 has a first end 1114 and the left lower tube 1102has a second end 1112. The first end 1114 includes a set of negativesplines 1108. A negative spline of the set of negative splines 1108 is adepression within the first end 1114 that is formed to lie parallel withthe vertical axis 1116. The brace 1106 includes the right brace shoulder1110A and the left brace shoulder 11106. The inner surfaces (not shown)of the right brace shoulder 1110A and the left brace shoulder 11106includes a set of positive splines configured for fitting within the setof negative splines 1108. A positive spline of the set of positivesplines is a raised vertically shaped block and is formed such that theraised positive spline fits within the negative spline depression.According to embodiments, the raised positive splines are smaller inarea than the negative spline depressions, such that when the rightbrace shoulder 1110A and the left brace shoulder 11106 are placed overthe first end 1114 and the second end 1112 of the right lower tube 1104and the left lower tube 1102, respectively, the right lower tube 1104and the left lower tube 1102 may be rotated horizontally, vertically androtationally within the fixture prior to a more permanent attachmentmechanism being applied, such as, for example, glue.

FIG. 12 illustrates a front cross-sectional view of the brace couplingthe right lower tube 1104 to the left lower tube 1102 of FIG. 11, inaccordance with an embodiment. As shown, the right lower tube 1104and/or the left lower tube 1102 may be adjusted in the horizontaldirection 1204. Further, the right lower tube 1104 and/or the left lowertube 1102 may be adjusted in the vertical direction 1202 in relation tothe brace 1106, in accordance with an embodiment.

FIG. 13 illustrates a side perspective view of the left lower tube 1104and the brace 1106, in accordance with an embodiment. As shown, the leftlower tube 1104 may be adjusted in the horizontal direction 1204.

FIG. 14 illustrates an enlarged front cross-sectional view of the area Aof FIG. 12. More particularly, FIG. 14 shows the left lower tube 1104,the second end 1112 described herein, and the left brace shoulder 11106described herein. Further, the glue joint 1402 is positioned between theleft brace shoulder 11106 and the second end 1112, in accordance withone embodiment. The glue joints enable improved alignment of the leftand the right lower tubes 1102 and 1104 by allowing for horizontal,vertical and rotational adjustment in the fixture prior to glue beingset.

FIG. 15 illustrates a brace 1506 coupling the right lower tube 1504 tothe left lower tube 1502, in accordance with an embodiment. The brace1506 includes the center bridge 1508. The center bridge 1508 is insertedhorizontally at the top of the brace 1506. Before the center bridge 1508is glued into place, the right lower tube 1504 and the left lower tube1502 may be horizontally, vertically and/or rotationally adjusted. Inaccordance with an embodiment, the right lower tube 1504 and the leftlower tube 1502 may be adjusted by being slid in the horizontaldirection 1510 in relation to each other. Additionally, the right lowertube 1504 and the left lower tube 1502 may be rotationally adjusted,such as the rotational direction 1512.

FIG. 16 illustrates a side perspective view of the left lower tube 1502of FIG. 15, in accordance with an embodiment. FIG. 16 shows that beforethe glue is set at glue joints 1704, the brace 1506 may be rotationallyadjusted in the rotational direction 1602 or vertically adjusted in thevertical direction 1604.

FIG. 17 illustrates the center bridge 1508 of FIG. 15 inserted into thebrace 1506, which is capable of sliding in the horizontal direction1510. Thus, the bridge 1508 enables the width adjustment of the lowerfork, in accordance with embodiments. In one embodiment, either end ofthe bridge 1508 has attached thereto an end cap, such as the end cap1702. In one embodiment, the end cap 1702 is made of elastomer andfunctions to seal the hollow center bridge 1508.

Thus, embodiments provide a variety of lower fork alignment systemembodiments, allowing for the separate manufacture of the right lowertube, the left lower tube, and the brace and/or center bridgeincorporated therein. By enabling this separate manufacture of these keycomponents, each component may be more precisely and individuallyaligned relative to other components. The individual alignmentmechanisms described herein enable the fork legs to be aligned in thesame horizontal and vertical plane, thereby allowing for smoother forkoperations. Thus, embodiments provide at least two axis of alignmentwhereby the brace may be assembled onto the lower fork legs andconstrained once the brace is bolted to the lower fork legs.

It should be noted that any of the features disclosed herein may beuseful alone or in any suitable combination. While the foregoing isdirected to embodiments of the present invention, other and furtherembodiments of the invention may be implemented without departing fromthe scope of the invention, and the scope thereof is determined by theclaims that follow.

What we claim is:
 1. A brace for coupling a right lower tube and a leftlower tube of a lower fork, said brace comprising: a right braceshoulder, said right brace shoulder including a set of positive splinesconfigured for fitting within a set of negative splines disposed in saidright lower tube; and a left brace shoulder, said left brace shoulderincluding a set of positive splines configured for fitting within a setof negative splines disposed in said left lower tube.